Manufacture of zircon refractories



f'atnted Sept. 18, 1928.

i an my ms unv'rblv, or. m'grncnnn, NEW JERSEY.

- MAI N'UFAOTURE OFZIRCON BEFRACTORIES.

No Drawing.

This invention relates to the manufacture of refractories of zircon. Zircon or zirconium silicate. ZrSiO,, is not only highly refractory and hence suitable for use in fur- 5 nace-linings and places where exceedingly.

high temperatures must be withstood, but it is also. relatively inert at high temperatures and therefore is excellently adapted for use .in metallurgical rocesseswhere the Rfractory must not on y withstand high temperatures without deformation, but must also withstand the corrosive action of molten slags'and metals. Unfortunately, however, zircon is exceedingly difiicultto mold and handle, in the unburned condition and no crucibles and the various special sha es required of refractories, handled in t e unburned condition, and fired to produce a hard, strong true product which-can be readily used wherever refractories of this nature are needed. In carrying out my invention I finely grind a portion of zircon in the presence of a deflocculent, add coarserzircon, make the mixture moldable by the addition of a gum: or fixative, mold the resultant mass to therequired shapes, dry themand fire to a temperature high enough to sinter the zircon.. As a specific example of the manufacture ofzircon refractories under the tion the following is given:

present invencon, of approximately 100 mesh and fi ner, known in the tradeas fine, and grind it in a ball mill with water containing. fromjo'netenth totwo percent tannic acid, continuing the grinding'until the zircon is very finely ground. Lignin, gallo-tanmc acid, gallic J acid or other similar or anic de'flocculents mightbe' substituted for t e tannic acid. To

- one'part oftln's groundmaterial I then-add one part of'fine zircon and two parts of a granular zircon of 40 mesh and coarser and mix the who e.- In making up small uantities ofthe refractory this mixture is t on dried and-a 'semi-drymoldable. batch made by addingfromtwoto ten percent by press or by hand. When ,peratures, but because of the low shrinkage Application filed June 27, 1925. Serial No. 40,098.

weight of water containing one-half to two percent of dextrine, the amount varying with the molding pressure to be applied. Other gums or organic fixatives or binders such as tragacanth, arabic, tar, molasses, pre- 0 pared fixatives, such as glutrin etc, might be substituted for the dextrine. Where the refractory is made in large quantities and it is not feasible to dry the ground batch the amount of water in the batch is calculated and the proper amount of water addedwith the fixative accordingly; After the fixative is added, the batch is thoroughly mixed in a suitable mixer, preferably one of the Werner & Pfeidler type, and the moist material then pressed into shape in a power a hand press is used w1th relatively light pressures and a relatively large percentage of fixative used, care should be taken when the shapes are removed from themold or die to place a sheet of paper between them and the dr ing pallet, as otherwise the shapes will sticl; to the pallet. ,When a power press is used and relatlvely little binder,- this precaution is not necessary. Y

After drying the shapes are hard and firmand may be readily handled and set in the ployed for special products. I take natural zirconium s1l1cate,-or z1r- By means of the above described method I have been enabled to produce wholly satisfact'ory bricks and other shapes which are made entirel ,of zircon. B omittin the specific molding step and a ding su cient water I can make a paste to be used as a cement for refractory uses. Such a cement is 'admirablyadapted for use at hi h temperatures not only because of its re ractory properties and its inertness at high temof zircon. When tannic acid orits equivalent is employed 5 as described above, this cement also has a very high binding strength in the dry and unfired state. The proportions given above have been found by actual 110 and to be expected.

I claim: I

1. The method of makin zircon refractories which comprises fine y grinding zircon in the presence of water containing an organic deflocculent, adding ranular zircon and an organic binder and s aping and firing the resultant product.

2. The method of makin zircon refractories' which comprises fine y grinding zircon in'the presence of water containing tannic acid, adding granular zircon, making a semi-dry batch of the mixture by the addition of dextrine,.and shaping and firing the resultant roduct.

3. The metiiod of making zircon refractories which comprises grinding zircon in the presence of water containing from onetenth to two percent tannic acid, adding one art of un ound zircon of about 100 mesh eness an two parts of granular zircon of about 40 mesh fineness, making up a semidry batch by adding from two to ten per- 1 cent by weight of a water solution containing from one-half to two percent of dextrine based on the weight of the water, mixing the organic de y con and an organic binder, and-making a batch, molding it,and firing theresultant o shape to sinter the zircon.

4. The method of cement which comprises finely zircon in the occulent, adding granular zirpaste of the mixture. 5. A molded refractory shape made by finely grinding zircon in the (presence of water containing an organic molding the mixture and firing the shape to sinter the zircon. I

6. The method of makin zircon refractories which comprises fine y grinding zircon in the presence of water containing an organic deflocculent-,'adding granular zircon, and shaping and firingthe resultant product. v

7 The method of making zircon refractories which comprises finely grinding zircon in the resenceof-water containing an organic eflocculent, adding granular zircon and a binder, and shaping and firing the resultant product. I

In testimony whereof I aifix my signature.

' r. nor HIMES M INTOlI.

making a refractory resence of water containing an 

